Ultra High Pressure Hydraulic Pipe Cutter for Wellbore Casing

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Solution Overview

Problem

Current methods for cutting oil and gas well casings and liners during abandonment are hazardous due to the use of heat-based tools, which can ignite explosive gases and require extensive excavation and multiple passes, leading to inefficiencies and safety concerns.

Innovation Solution

An ultra-high pressure cutting device that uses fluid and abrasive to cut through wellbore components from the inside out, reducing the risk of ignition and eliminating the need for excavation and multiple passes by cutting multiple layers in a single pass.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If heat-based cutting tools (cutting torch) are used to cut casing and liners, then the cutting operation can be performed, but the risk of igniting explosive or flammable gas or fluid increases significantly

Engineering Contradiction:

Improvecutting capabilityVSAvoidignition risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces thermal cutting mechanisms (cutting torch) with a mechanical cutting system consisting of a rotating cutter head with cutting elements that physically cut through the casing and liner materials, eliminating the ignition risk associated with heat-based methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs ultra-high pressure fluid (water jet) to erode and cut through the casing and liner materials, providing a non-thermal cutting method that eliminates sparks and ignition risks while maintaining effective cutting capability

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If extensive excavation is performed to access wellbore components for cutting, then the cutting operation can be performed safely, but the time and complexity of the operation increases

Engineering Contradiction:

ImprovesafetyVSAvoidexcavation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Instead of excavating from the outside to access the wellbore for cutting, the patent inverts the approach by inserting the cutting device into the wellbore from the top and cutting the casing and liner from the inside out, eliminating the need for extensive excavation

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The cutting device is designed to be inserted inside the existing wellbore structure, with the cutter head positioned within the casing to perform cutting operations from the interior, allowing the tool to operate within the confined space without external excavation

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If metal blades are used to cut through casing layers, then cutting can be performed, but the tool becomes jammed if the casing moves during cutting

Engineering Contradiction:

Improvecutting capabilityVSAvoidjaming risk

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses ultra-high pressure water jet to cut the casing and liner materials, replacing mechanical metal blades with a fluid-based cutting mechanism that is not susceptible to jaming when the casing moves or shifts during the cutting operation

Inventive Principle:

Principle #29Pneumatics and hydraulics

4Reliability

If multiple passes are used to cut through different layers (casing and liner), then complete removal is achieved, but the operation time and complexity increases

Engineering Contradiction:

Improvecomplete removalVSAvoidcutting efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The cutting device is designed with a universal cutter head capable of cutting through multiple different materials (casing steel and cement liner) using the same ultra-high pressure water jet mechanism, allowing both layers to be removed in a single continuous operation without requiring different tools or multiple passes

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The ultra-high pressure cutting device effectively cuts through steel and cement layers without heat or sparks, enhancing safety and efficiency by minimizing excavation and allowing for use in extreme conditions.

Implementation Method 1

Ultra-high pressure fluid, optionally in combination with an abrasive, is used to cut through the wellbore

Methodology Applied

Scientific EffectErosion: Erosion

Implementation Method 2

Ultra-high pressure fluid, optionally in combination with an abrasive, is used to cut through the wellbore

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS8820396B2Ultra high pressure hydraulic sublevel pipe cutter

Publication Date: 2014.09.02 NUWAVE IND

AI summary

An ultra-high pressure (UHP) cutting device for insertion into a wellbore for cutting the casing of the wellbore from within the wellbore is provided. The cutting device comprises a UHP hose connector for connection with a UHP hose in communication with a fluid source; a rotatable UHP tube with a top end in fluid communication with the UHP hose connector and a bottom end opposite the top end; a rotating means in operational communication with the UHP tube for rotating the UHP tube during operation of the cutting device; and a cutter head in fluid communication with the bottom end of the UHP tube.